Packaging assembly comprising an interior bond

ABSTRACT

A packaging assembly including a flexible outer shell layer and a flexible inner cushioning layer in overlapping relation with each other and comprising at least one interior bond that bonds an interior area of the outer shell layer to an interior area of the inner cushioning layer.

BACKGROUND

Packaging assemblies, e.g., shipping containers, padded mailers, and thelike, have found increasing use as more and more items are purchasedonline and are shipped to the end-user.

SUMMARY

In broad summary, herein is disclosed a packaging assembly including aflexible outer shell layer and a flexible inner cushioning layer inoverlapping relation with each other and comprising at least oneinterior bond that bonds an interior area of the outer shell layer to aninterior area of the inner cushioning layer. These and other aspectswill be apparent from the detailed description below. In no event,however, should this broad summary be construed to limit the claimablesubject matter, whether such subject matter is presented in claims inthe application as initially filed or in claims that are amended orotherwise presented in prosecution.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary packaging assembly with anitem disposed in a ready-for-packaging condition.

FIG. 2 is a side view of an exemplary packaging assembly with an itemdisposed in a ready-for-packaging condition.

FIG. 3 is a side view of an exemplary packaging assembly as disclosedherein.

FIG. 4 is a side view of an exemplary packaging assembly andillustrating methods of packaging an item within the construction.

FIG. 5 is a side view of another exemplary packaging assembly asdisclosed herein.

Like reference numbers in the various figures indicate like elements.Some elements may be present in identical or equivalent multiples; insuch cases only one or more representative elements may be designated bya reference number but it will be understood that such reference numbersapply to all such identical elements. All figures and drawings in thisdocument are not to scale and are chosen for the purpose of illustratingdifferent embodiments of the invention. In particular the dimensions ofthe various components are depicted in illustrative terms only, and norelationship between the dimensions of the various components should beinferred from the drawings, unless so indicated. Although terms such asfirst and second may be used in this disclosure, it should be understoodthat those terms are used in their relative sense only unless otherwisenoted.

Terms such as outward and inward are defined in relation to thepackaging assembly as packaged (e.g., wrapped) around an item, withinward denoting toward the item and with outward denoting away from theitem. For clarity of description, these terms are retained even indescriptions of the packaging assembly and components thereof, prior tothe assembly being packaged around an item.

As used herein as a modifier to a property or attribute, the term“generally”, unless otherwise specifically defined, means that theproperty or attribute would be readily recognizable by a person ofordinary skill but without requiring a high degree of approximation(e.g., within +/−20% for quantifiable properties). The term“substantially”, unless otherwise specifically defined, means to a highdegree of approximation (e.g., within +/−10% for quantifiableproperties). The term “essentially” means to a very high degree ofapproximation (e.g., within plus or minus 2% for quantifiableproperties; it will be understood that the phrase “at least essentially”subsumes the specific case of an “exact” match. However, even an “exact”match, or any other characterization using terms such as, e.g., same,equal, identical, uniform, constant, and the like, will be understood tobe within the usual tolerances or measuring error applicable to theparticular circumstance rather than requiring absolute precision or aperfect match.

DETAILED DESCRIPTION

Disclosed herein is a packaging assembly 1. Packaging assembly 1comprises a flexible outer shell layer 20 and a flexible innercushioning layer 10, as shown in exemplary embodiment in perspectiveview in FIG. 1 and in side view in FIG. 2. By flexible is meant thatlayers 10 and 20, when manipulated individually and/or if manipulatedsimultaneously as a stacked pair of layers, can be easily bent, folded,and so on, by hand by a human user, without the use of any special toolsor the like.

Flexible layers 10 and 20 are in overlapping relation with each other,as shown in exemplary embodiment in FIGS. 1 and 2. By overlappingrelation is meant that, when layers 10 and 20 are in aready-for-packaging condition (e.g., flat on a suitable horizontalsurface, as in FIGS. 1 and 2) at least 40% of the total area of layer 10overlaps layer 20, and vice versa. In various embodiments, at least 60,80, 90 or 95% of the total area of layer 10 overlaps layer 20, and viceversa. In some convenient embodiments, layers 10 and 20 are coextensive,meaning that they share the same shape and size with essentially 100% oftheir area in overlapping relation with each other, as in the exemplaryarrangement of FIG. 1. In many convenient embodiments, packagingassembly 1 and layers 10 and 20 thereof may be at least generallyrectangular and may exhibit four major terminal edges. In some specificembodiments, layers 10 and 20 may be at least generally square, as shownin exemplary embodiment in FIG. 1.

Packaging assembly 1 comprises at least one interior bond 30 that islocated between inner cushioning layer 10 and outer shell layer 20, asshown in exemplary embodiment in FIGS. 1 and 2. As shown in furtherdetail in FIG. 3, interior bond 30 bonds an interior area 21 of outershell layer 20 to an interior area 11 of inner cushioning layer 10.Other area(s) 22 of outer shell layer 20 and area(s) 12 of innercushioning layer 10 remain unbonded as evident in FIG. 3. The provisionof at least one interior bond 30 in this manner allows shell layer 20and cushioning layer 10 to be provided to an end user and handled by theend user as a multilayer stack that is held together by the at least oneinterior bond 30. However, the unbonded areas 22 and 12 of the shelllayer 20 and the cushioning layer 10 can be manipulated separately andindividually, which is advantageous as discussed later herein.

By at least one interior bond is meant a bond (i.e., one or more bonds,whether direct or indirect) between the shell layer 20 and thecushioning layer 10, that is located in an interior area of each layer.In other words, no portion of bond 30 will extend to a terminal edge oflayer 10 or layer 20. Rather, each layer will include a “picture-frame”border of unbonded material (areas 12 and 22, in FIG. 3). Left, right,fore and aft unbonded areas, that are not bonded by interior bond 30 andthat collectively comprise an unbonded picture-frame border, are alsoindicated (as 1, r, f and a) in FIG. 1.

In some embodiments, an interior bond will occupy (in terms of totalactual bonded area) less than 40% of the total area of each layer. Invarious embodiments, an interior bond 30 may occupy less than 35, 30,25, 20, 15, 10, 8, 6, 4 or 2% of the total area of each layer. Infurther embodiments, an interior bond 30 may occupy at least 0.5, 1.0,1.5, 3.0, 5.0, 7.0, 13, 18, 23, or 28% of the total area of each layer.By way of a specific example, the exemplary interior bond 30 depicted inFIG. 1 occupies approximately 3% of the total area of each layer.

In some embodiments the at least one interior bond 30 will overlap withthe geometric center of shell layer 20 and/or the geometric center ofcushioning layer 10 (in either case, this means that with the packagingassembly 1 in a ready-for-packaging configuration, the geometric centerof the layer will pass through some portion of interior bond 30). Insome such embodiments, the at least one interior bond will overlap withthe geometric center 5 of packaging assembly 1 as indicated in exemplarymanner in FIG. 2. In some such embodiments, the geometric center oflayer 10, layer 20, and/or packaging assembly 1 will pass through (i.e.,will coincide with) the geometric center of interior bond 30, again asin FIG. 2. In instances in which the at least one interior bond 30 isprovided by multiple individual bonds with unbonded areas in between (asdiscussed below), for purposes of establishing a condition of thegeometric center of bond 30, the geometric center of the total areaoccupied by the multiple bonded areas that collectively make up bond 30will be used. Thus, in some instances the geometric center of interiorbond 30 may, e.g., pass through an unbonded area, e.g., in between twoadjacent bonded areas. An interior bond 30 may have any suitable shape;e.g., generally rectangular (e.g., square) as in the exemplaryembodiment of FIG. 1.

In some embodiments, an at least one interior bond may take the form ofa single, continuous bond (e.g., as shown in exemplary embodiments inFIGS. 1 and 2). In other embodiments, an at least one interior bond maytake the form of multiple discrete bonds that are provided in a desiredpattern along selected areas of layers 10 and 20, with the multiplediscrete bonds serving as the at least one interior bond 30 andcollectively exhibiting a total bonded area that meets the requirementslisted above.

In some embodiments an at least one interior bond may take the form of amelt-bond between the shell layer 20 and the cushioning layer 10. A meltbond may be achieved, e.g., by way of temperature, ultrasonic energy, orany suitable means, combined, e.g., with appropriate pressure as needed.Thus in some embodiments an at least one interior bond 30 may take theform of a pattern of ultrasonic welds between layers 10 and 20.

In some embodiments an adhesive may be used to provide interior bond 30,e.g., a liquid adhesive, a glue, a hot melt adhesive, or the like,applied, e.g., as a strip, as a set of dots, and so on. In someconvenient embodiments an at least one interior bond 30 may be providedby a double-faced pressure-sensitive adhesive, e.g., a piece, patch orstrip of such an adhesive, as indicated in FIGS. 1-3. In suchembodiments a major inward surface 33 of adhesive 30 may face toward,and be bonded to, a major outward surface 14 of cushioning layer 10; amajor outward surface 34 of adhesive 30 may face toward, and be bondedto, major inward surface 24 of shell layer 20.

A packaging assembly 1 as disclosed herein may be used according to thegeneral method depicted in generic, exemplary embodiment in FIG. 4. As apreliminary step, packaging assembly 1 can be positioned generally flat(e.g., on any suitable horizontal surface) with cushioning layer 10facing up, and an item 100 to be packaged may be positioned as desired(typically, centered over the geometric center 5 of packaging assembly1) atop cushioning layer 10 as shown in FIGS. 2 and 4. With reference tothe side view of FIG. 4, as a first (“A”) step of packaging item 100within packaging assembly 1, areas 12 of cushioning layer 10, which arenot bonded to shell layer 20 and are thus free to be moved independentlyof shell layer 20, are folded over the top surface of item 100 in thegeneral manner indicated by block arrows A of FIG. 4. At this point, thefolded-over areas of cushioning layer 10 may be secured (e.g., withpressure-sensitive tape or the like) to each other, and/or to item 100,if desired.

An additional A step can then be performed with the remaining unbondedareas of cushioning layer 10. It will be understood that FIG. 4 is across-sectional view that can only show the folding of certain areas ofthe layers. Thus, with reference to the top, perspective view of FIG. 1,the above-described first A step may involve folding over the left (l)and right (r) areas of cushion layer 10. The additional A step will theninvolve folding over the fore (f) and aft (a) areas of cushion layer 10,noting that folded-over portions of the left and right areas may bepresent atop the fore and aft areas as the result of the first A step,and will accordingly be folded along with the fore and aft areas in thesecond A step.

The result of performing these steps is that cushioning layer 10 becomeswrapped around the item 100 in a protective configuration, by which ismeant that layer 10 surrounds item 100 on all sides so that no portionof item 100 is reachable from the outside along a line that does notpass through at least a portion of cushioning layer 10. (Depending on,e.g., the size of the item relative to cushioning layer 10, there may bemultiple layers of cushioning layer 10 on at least one side of the item100).

In some embodiments, the cushioning layer can be secured (e.g., withpressure-sensitive adhesive tape, or with mechanical means such asstring or staples) in the protective configuration. However, in someembodiments the cushioning layer may merely be held in thisconfiguration while subsequent manipulations are performed with shelllayer 20, so that shell layer 20, when in its final configuration asdescribed below, holds and maintains cushioning layer 10 in itsprotective configuration.

After inner cushioning layer 10 has been wrapped around item 100 into aprotective configuration as described above, a “B” packaging step can beperformed in which areas 22 of outer shell layer 20 that are not bondedto inner cushioning layer 10 (and that thus remained undisturbed duringthe above-described steps of folding the cushioning layer), can befolded over the outward surface of the portions of cushioning layer 10that are atop item 100, in the general manner indicated by block arrowsB of FIG. 4. An additional B step can then be performed with anyremaining unbonded areas of outer shell layer 20, in similar manner asdiscussed above for remaining unbonded areas of cushioning layer 10.

The result of the above-described steps of wrapping outer shell layer 20around inner cushioning layer 10 will be that outer shell layer 20 isnow in an encapsulating configuration. By this is meant that the outershell layer 20 completely surrounds the inner cushioning layer on allsides so that no portion of inner cushioning layer 10 (or item 100) isreachable from the outside along a line that does not pass through atleast a portion of shell layer 20. After the outer shell layer has beenfolded into an encapsulating configuration, outer shell layer 20 can besecured (e.g., with pressure-sensitive adhesive tape) in the protectiveconfiguration.

It will be understood that the above arrangements may be modified in anysuitable manner. For example, in some embodiments the edges of thecushioning layer and/or the shell layer may be cut by an end user, e.g.,with scissors, to reduce the total area of the layer(s) and/or or tomodify the shape of the layer(s) in view of the size and/or shape of theitem to be packaged. In some embodiments, multiple items 100, ratherthan a single item 100, may be packaged in a single packaging assemblyof the general type described herein.

In some embodiments packaging assembly 1 may optionally comprise atleast one area of pressure sensitive adhesive 40 that is provided on amajor inward surface 13 of cushioning layer 10 that faces away fromouter shell layer 20, as shown in exemplary embodiment in FIG. 5.Pressure-sensitive adhesive 40 can comprise a major adhesive surfacethat faces away from outer shell layer 20; an item 100 to be packagedcan be contacted with (e.g., disposed on) the major adhesive surface ofadhesive 40. Adhesive 40 thus can hold item 100 so that item 100 hasless tendency to shift or slide during the above-described packagingprocess. Any such adhesive 40 need not necessarily be extremely strong,or need to hold item 100 permanently; rather, the adhesive may onlyserve to momentarily tack down item 100 until item 100 is secured withinpackaging assembly 1 as described above. If desired, adhesive 40 may bea pressure-sensitive adhesive of the type typically described asrepositionable, so that item 100 can be separated from adhesive 40 whendesired, without damaging or marring the surface of item 100.

An adhesive 40 may be provided by, for example, a piece of double-facedadhesive tape or the like. Such an adhesive can have any suitable sizeor shape, and/or can be provided by a single piece of adhesive tape orby several pieces working in combination. If desired, packaging assembly1 may be provided to an end user with a release liner in place over themajor adhesive surface of adhesive 40 (i.e., the “top” surface as shownin FIG. 5); such a release liner can be removed by the end user when anitem is ready to be contacted with the adhesive.

In some embodiments, any such adhesive 40 will occupy (in terms of totalactual bonded area) less than 40% of the total area of outer shell layer20. In various embodiments, any such adhesive 40 may occupy less than35, 30, 25, 20, 15, 10, 8, 6, 4 or 2% of the total area of each layer.In further embodiments, any such adhesive may occupy at least 0.5, 1.0,1.5, 3.0, 5.0, 7.0, 13, 18, 23, or 28% of the total area of each layer.

A packaging assembly 1 as disclosed herein may be provided in anysuitable format. In some embodiments, multiple packaging assemblies 1can be provided, e.g., stacked into a batch, e.g., in a box or othersuitable container, from which successive packaging assemblies 1 can beremoved for use. In some embodiments, multiple packaging assemblies 1may be provided as a roll good in which outer shell layer 20 and innercushioning layer 10 are co-rolled with each other. The presence of theat least one interior bond between these two layers will retain thelayers in their proper configuration (e.g., minimizing any tendency ofthe layers to slip, shift, telescope or the like) relative to eachother. An end user can merely cut off a desired section of the roll goodfor use in packaging any particular item. In various embodiments,packaging assembly 1 may exhibit a total thickness of between about 1/32inch and about 2 inches, or between about 7/64 inch and about 2 inches,or between about ¼ inch and about 1 inch.

Flexible outer shell layer 20 can be any desired layer that provides atleast some of the features described herein. In some embodiments, theouter layer is a single layer. In some embodiments, the outer layerincludes multiple layers. As is described in greater detail below, insome embodiments, the outer layer is at least one of single-ply,double-ply, or triple-ply and/or single layer or multi-layer. Themulti-layer constructions can include any desired number of layers.

In embodiments where the outer layer is single ply, the outer layermaterial may be a heavy weight paper (such as, for example, kraft paperor the like), a plastic film (such as, for example, MYLAR™), a nonwovenmaterial (such as, for example, TYVEK™), or a treated paper (such as,for example, aluminized paper).

In some embodiments, the outer layer includes a paper layer, which canbe coated paper, Kraft paper, or higher quality paper such as Bond orwhite paper. In some embodiments, the paper may be printable and/ormetallized to obtain a decorative packaging material. In someembodiments, the metallized paper layer may also be provided withgraphics thereon.

In some embodiments, the outer layer includes a plastic. In someembodiments, the plastic is printed, embossed, structured, orreinforced. In some embodiments, the plastic includes at least one ofpolypropylene, polyethylene, polyurethane, polyester, and/or a copolymerof any of these. In some embodiments, the polyethylene is at least oneof a low density polyethylene, a metallocene linear low densitypolyethylene, linear low density polyethylene, a low densitypolyethylene, polypropylene, olefinic block copolymer(s), a high densitypolyethylene, and/or copolymers and/or blends of any of these.

In some embodiments, the plastic is a thermoplastic and/or olefinmaterial. The plastic may be oriented uniaxially or biaxially to imparthigh-strength thereto. A biaxial orientation may be preferred forgreatest strength. One or more of the surfaces of the plastic layer maybe corona discharge treated to render one or more of them receptive toinks and printing. Further, if a decorative package is desired, theplastic may be metallized as by vacuum deposition.

In some embodiments, the outer layer is a multilayer plastic film. Insome embodiments, the multilayer film includes one to seven layers. Insome embodiments, the multilayer film includes more than seven layers.In some embodiments, the multilayer assembly includes at least one ofpolypropylene, polyethylene, cyclic olefin copolymers, polyurethane,polyester, polyamide, and/or a copolymer of any of these. In someembodiments, at least the layer of shell layer 20 that provides theinward major surface 24 of shell layer 20 may contain a polymer thatenables melt-bonding to the material of cushioning layer 10. Someexemplary layers capable of providing melt-bonding include, for example,those comprising low density polyethylene, linear low densitypolyethylene, metallocene linear low density polyethylene,polypropylene, olefinic block copolymers, and/or copolymers and/orblends of any of these. One or more of the layers of a multilayer outerlayer may impart to the overall outer layer assembly a low gaspermeability that enables air retention in the cushioning layer (e.g.,bubble wrap). One or more of the layers in the multilayer assembly mayprovide tear resistance properties. Some exemplary layers capable ofproviding tear resistance include, for example, those comprising lowdensity polyethylene, linear low density polyethylene, metallocenelinear low density polyethylene, polypropylene, olefinic blockcopolymers, polyamide, polyester, polyurethane, and/or copolymers and/orblends of any of these.

In some embodiments, the outer layer is a two-ply or two-layer assemblyor laminate. In some embodiments, the two-ply or two-layer assembly orlaminate is a paper/plastic assembly or laminate. In some suchembodiments, a paper layer is laminated to a plastic film layer. Anotherexemplary two-ply or two-layer outer layer or assembly is a laminatethat includes a water impermeable plastic film having a first coronadischarge treated surface that is adhesively cold laminated to the paperlayer.

In some embodiments, the outer layer is three-ply. In some embodiments,the two-ply material(s) described above may further include anadditional paper layer to form a paper-plastic-paper, three-ply laminatesheeting. The extra paper layer may be desirable for packaging objectswith pointed edges or simply when a packaging material with morestrength is desired. As the paper layers form the inner and outer sidesof the packaging material, they can easily be printed with graphics orother indicia prior to application of the cushioning and/or cohesivematerial(s). This enables the packaging material to have one appearanceon the outside of the package and another, different appearance on theside of the material that faces the item being shipped. Anotherexemplary outer layer is a three-ply laminate that includes a waterimpermeable plastic film, e.g., having first and second corona dischargetreated surfaces that are adhesively cold laminated to first and secondpaper layers. In some embodiments, the outer layer is more than threelayers.

It may also be desirable that outer shell layer 20 may have an outermajor surface 23 (or a portion thereof) that is a printable majorsurface so that logos, messages, advertisements, emblems, trademarks oraddressee information (or a location, e.g., rectangular box, that isdesignated for putting address information thereinto) etc., may beprinted, e.g., on outward surface 23 of outer shell layer 20. In someembodiments, the outer layer may include one or more corona dischargetreated surface to render it receptive to inks.

Thus in at least some embodiments, the outer surface 23 of shell layer20 should be able to be provided with indicia or other printedinformation. If the material itself is not inherently receptive to suchprinted information, it can be treated to be receptive. For example, aplastic film of polyethylene that has the outer surface treated by acorona discharge can then be printed or provided with printed indicia.It is also possible, although less preferred, that the indicia beapplied to the packaging material by an adhesive-backed sticker, labelor the like.

In some embodiments, the outer shell layer 20 has a thickness of greaterthan about 0.5 mils, or greater than 0.75 mils, or greater than 1 mil,or greater than 1.25 mils, or greater than 1.5 mils, or greater than1.75 mils, or greater than 2 mils. In some embodiments, the outer layerhas a thickness of less than 5 mils, or less than 4.5 mils, or less than4.0 mils, or less than 3.5 mils, or less than 3 mils. In someembodiments, the outer layer has a thickness of between about 0.5 milsand about 5 mils, or between about 1 mil and about 4 mils, or betweenabout 2 mils and about 3 mils. In some embodiments where the outer layeris paper, the outer layer has a thickness of greater than about 3 mils.

In some embodiments, at least a portion, and in some instances,substantially the entire, outer major surface 23 of outer layer 20 iswritable (e.g., can be written on with conventional writing instrumentssuch as pens, pencils, and/or markers). In some embodiments, this can beachieved by selecting materials for the outer layer that inherentlyprovide that characteristic. In some embodiments, this can be achievedby treating at least a portion of the surface of the selected outerlayer to impart desired writability and/or adhesion (e.g., applying anadhesive-backed paper sheet or label). In some embodiments, one or morevarnishes are applied to or included in the outer layer construction.Applying or including a varnish layer to a treated surface may impartwritability by, for example, changing surface roughness and, thus, thesurface coefficient of friction. In some embodiments, the varnishchemistry may be tailored to achieve compatibility with an ink and/orcohesive formulation. In addition, if desired a decorative package isprovided in an embodiment wherein the exterior surface of the outerlayer is metallized or aluminized. If a silver finish is desired, analuminized surface may be preferred. Other metallizing treatments, e.g.,with copper, iron, or alloys, can be used when other colors are desired.

In some embodiments, the outer shell layer 20 is water impermeable. Insome embodiments, the outer layer is sufficiently tear and scuffresistant such that a wrapped item remains secure and protected duringshipping and handling. In some embodiments, the outer layer includes oneor more materials providing at least one of insulation from thermal oracoustic shock and/or radiation protection.

It is desired that the packaging assembly 1 should provide some degreeof shock and/or impact resistance to prevent damage to an item beingshipped. The herein-described inner cushioning layer 10 can be anysuitable layer that provides cushioning of an item 100 that is packagedin (e.g., wrapped in) a packaging assembly 1. In some embodiments, it isdesired that the cushioning layer have a relatively low profile to avoidundesirable bulk which could make packaging more complicated and/orstorage more challenging. In some embodiments, the cushioning layer hasa thickness of between about 1/32 inch and about 2 inches. In someembodiments, the cushioning portion has a thickness of greater thanabout 1/32, or about 7/64 inch, or about ¼ inch, or about ½ inch, orabout ¾ inch, or about 1 inch. In some embodiments, the cushioningportion has a thickness of less than about 2 inches, or less than about1 inch, or less than about ¾ inch, or less than about ½ inch.

In some embodiments, the inner cushioning layer 10 is a single layer. Insome embodiments, the cushioning layer or portion includes multiplelayers. In some embodiments, the cushioning layer 10 includes bubblewrap. As used herein, the term “bubble wrap” is meant to include allpliable, polymeric materials that include spaced, protruding air orgas-filled bubbles that are capable of providing cushioning. The term ismeant to include those items referred to as bubble wrap, bubble pack,bubble paper, bubble film, air or gas bubble packing, bubble wrapping,and aeroplast. Some embodiments of bubble wrap include a first thinflexible layer 15 of plastic or polymeric material having a plurality ofspaced apart recesses in one surface (so that layer 15 is significantlynon-planar) and a second thin flexible, relatively flat “film” layer 16of plastic material. The second “film” layer 16 is bonded to the onesurface of the first layer 15 to seal air or gas into the recesses toform “bubbles”, as shown in detail in FIG. 3 and as will be readilyunderstood by artisans in the field. The bubble wrap can include, forexample, polyethylene as the plastic material for example, a linear lowdensity polyethylene, a low density polyethylene and/or a high densitypolyethylene. However, other suitable plastics or polymers may also beused, such as, for example, polypropylene. Some commercially availablebubble wraps include, for example, Scotch™ Cushion Wrap. Bubble wrapsthat may be particularly suitable are described in U.S. ProvisionalPatent Application No. 62/786,592, which is incorporated herein in itsentirety. As noted above, in some embodiments, an inner cushioning layer10 can include a bubble portion 15 and a film portion 16 that combine toform a bubble wrap. In some embodiments, the bubble wrap has a thicknessof between about 1/32 inch and about ½ inch. In some embodiments, thebubble wrap has a thickness of greater than about 1/32, or about 7/64inch, or about ¼ inch. In some embodiments, the bubble wrap has athickness of less than about ½ inch, or less than about ¼ inch, or lessthan about ⅓ inch.

Further details of materials (e.g., bubble wraps) that can be used as aninner cushioning layer, and of materials that can be used as an outershell layer, are described in U.S. Provisional Patent Applications Nos.62/620,031 and 62/794,617 and in the resulting International (PCT)Patent Application Publication No. WO 2019/142172, all of which areincorporated by reference herein in their entirety.

In some embodiments, the inner cushioning layer 10 may include at leastone layer of flexible foam. Exemplary flexible foams can include, forexample, polyethylene, polyester, acrylic, polyurethane, orpolypropylene. Regardless of the specific composition and/or geometricformat (e.g., whether comprising bubble wrap, flexible foam, or both),an inner cushioning layer 10 as described herein will be distinguishedfrom a so-called “cohesive” layer that is purposefully configured toadhere to itself in the manner described, e.g., in U.S. ProvisionalPatent Applications Nos. 62/620,031 and 62/794,617 and in the resultingInternational (PCT) Patent Application Publication No. WO 2019/142172.In particular, inner major surface 13 of inner cushioning layer 10 asdisclosed herein, will not exhibit any property of being “cohesive”,self-adhering, self-bonding, or any like term or property.

It will be apparent to those skilled in the art that the specificexemplary elements, structures, features, details, configurations, etc.,that are disclosed herein can be modified and/or combined in numerousembodiments. All such variations and combinations are contemplated bythe inventor as being within the bounds of the conceived invention, notmerely those representative designs that were chosen to serve asexemplary illustrations. Thus, the scope of the present invention shouldnot be limited to the specific illustrative structures described herein,but rather extends at least to the structures described by the languageof the claims, and the equivalents of those structures. Any of theelements that are positively recited in this specification asalternatives may be explicitly included in the claims or excluded fromthe claims, in any combination as desired. Any of the elements orcombinations of elements that are recited in this specification inopen-ended language (e.g., comprise and derivatives thereof), areconsidered to additionally be recited in closed-ended language (e.g.,consist and derivatives thereof) and in partially closed-ended language(e.g., consist essentially, and derivatives thereof). To the extent thatthere is any conflict or discrepancy between this specification aswritten and the disclosure in any document that is incorporated byreference herein but to which no priority is claimed, this specificationas written will control.

What is claimed is:
 1. A packaging assembly comprising a flexible outershell layer and a flexible inner cushioning layer in overlappingrelation with each other and comprising at least one interior bond thatbonds an interior area of the outer shell layer to an interior area ofthe inner cushioning layer.
 2. The packaging assembly of claim 1,wherein the inner cushioning layer comprises bubble wrap that includes afilm portion and a bubble portion that includes air or gas-filledbubbles, wherein the film portion of the bubble wrap is adjacent to theouter shell layer, and wherein the interior bond bonds a discrete areaof the film portion of the bubble warp to the discrete portion of theouter shell layer.
 3. The packaging assembly of claim 1 wherein the atleast one interior bond occupies less than 20% of the total area of theouter shell layer and less than 20% of the total area of the innercushioning layer.
 4. The packaging assembly of claim 1 wherein the innercushioning layer has a thickness of between about 1/32 inch and about 1inch.
 5. The packaging assembly of claim 1 wherein the outer shell layeris a multilayer structure.
 6. The packaging assembly of claim 1 whereinthe outer shell layer comprises at least one of paper, plastic, anonwoven, or combinations thereof.
 7. The packaging assembly of claim 1wherein the outer shell layer comprises at least one of polypropylene,polyethylene, polyurethane, polyester, and/or a copolymer of any ofthese.
 8. The packaging assembly of claim 1 wherein the outer shelllayer comprises an oriented or biaxially oriented organic polymericmaterial.
 9. The packaging assembly of claim 1 wherein the outer shelllayer comprises an outward major surface that is a writable surface. 10.The packaging assembly of claim 1 wherein the at least one interior bondbetween the outer shell layer and the inner cushioning layer is a meltbond.
 11. The packaging assembly of claim 1 wherein the at least oneinterior bond between the outer shell layer and the inner cushioninglayer is provided by at least one piece of double-facedpressure-sensitive adhesive.
 12. The packaging assembly of claim 1wherein the at least one interior bond between the outer shell layer andthe inner cushioning layer is a single interior bond that overlaps witha geometric center of the outer shell layer and a geometric center ofthe inner cushioning layer.
 13. The packaging assembly of claim 1wherein the at least one interior bond between the outer shell layer andthe inner cushioning layer occupies less than 10% of the total area ofthe outer shell layer and less than 10% of the total area of the innercushioning layer.
 14. The packaging assembly of claim 1 wherein theouter shell layer and the inner cushioning layer are at leastsubstantially co-extensive.
 15. The packaging assembly of claim 1further comprising at least one area of pressure-sensitive adhesive thatis provided on a major surface of the inner cushioning layer that facesaway from the outer shell layer, and wherein the pressure-sensitiveadhesive comprises a major adhesive surface that faces away from theouter shell layer.
 16. The packaging assembly of claim 15 wherein thepressure-sensitive adhesive comprises a release liner that is releasablydisposed on the entirety of the major adhesive surface of thepressure-sensitive adhesive.
 17. The packaging assembly of claim 1wherein the packaging assembly is provided as a roll good comprising theouter shell layer and the inner cushioning layer, co-rolled with eachother.
 18. A method of packaging an item using a packaging assemblycomprising a flexible outer shell layer and a flexible inner cushioninglayer in overlapping relation with each other and comprising at leastone interior bond therebetween, the method comprising: positioning thepackaging assembly with the inner cushioning layer facing upward;placing the item to be packaged on the inner cushioning layer so thatthe item overlaps a geometric center of the of the outer shell layer andthe inner cushioning layer; wrapping the inner cushioning layer aroundthe item into a protective configuration while the outer shell layerremains unmoving; optionally securing the inner cushioning layer in theprotective configuration; wrapping the outer shell layer around theinner cushioning layer that is in the protective configuration so thatthe outer shell layer is in an encapsulating configuration in which theouter shell layer completely envelopes the inner cushioning layer and inwhich the inner cushioning layer is retained in the protectiveconfiguration; and, securing the outer shell layer in the encapsulatingconfiguration.